stellar labs TC23 User manual

TC23
PN76882
3H Version
Capacity
Chart
TC23
1780K g
1.22 m
960 Kg
2.16 m
685 Kg
3.09 m
530K g
4.03 m
3920lb s
4.00 ft
2115 lbs
7.08 ft
1510 lbs
10.13 ft
1165lbs
13.22 ft
NOTICE
73929
WARNING
4189
Do not exceed equipment load charts and ratings.
Failure to follow equipment load charts and ratings
can result in death or serious injury.
Overload Hazard
Model TC23
Telescopic Crane
Owner’s Manual
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com
Subject to Change without Notication.
© 2016 Stellar Industries, Inc. Last Revision: 12/15/16
Installation • Assembly Drawings • Parts
Notice: A copy of this manual must remain with the equipment at all times.
For a printable download copy, please visit: www.stellarindustries.com

Page ii | Stellar®TC23 Telescopic Crane Owner’s Manual
Model TC23 Manual Revisions
Date of Revsion Section Revised Description of Revision
MODEL NO.SERIAL NO.
DATE
MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.
PN C5942
®
PATENT INFORMATION
http://www.stellarindustries.com/ip
Serial Tag
Location

Stellar®TC23 Telescopic Crane Owner’s Manual | Page iii
Table of Contents
Introduction .................................................................................................................. iv
Chapter 1 - Specications............................................................................................... 1
Model TC23-2H Specications ..................................................................................... 1
Model TC23-3H Specications ..................................................................................... 2
TC23-2H Capacity .........................................................................................................3
TC23-3H Capacity .........................................................................................................4
Chapter 2 - Installation .................................................................................................... 5
General Installation .......................................................................................................5
Installer Notice ............................................................................................................5
Torque Data Chart ..................................................................................................... 6
Installation Overview .................................................................................................. 7
TC23 Mounting Detail ...................................................................................................7
TC23 Installation Drawing - PN 76862 .......................................................................... 8
Flatbed Body Reinforcement ......................................................................................8
Control Kit .......................................................................................................................9
Control Kit Installation Drawing ................................................................................. 10
Control Kit with Winch Installation Drawing .............................................................11
TC Series Wiring Diagram ...........................................................................................12
Hydraulic Kit - PN 75815 .............................................................................................. 13
Hydraulic Kit with Winch - PN 75818 ..........................................................................14
Hydraulic Kit -Valve Bank ............................................................................................15
Valve Bank - PN 73943 ................................................................................................16
Valve Bank with Winch - PN 72666 ............................................................................ 17
TC Series Hydraulic Schematic .................................................................................. 18
Hydraulic Kit -Motor ....................................................................................................19
Hydraulic Kit -Pressure Transducer ............................................................................. 20
Hydraulic Kit Installation Drawing - PN 76479 .......................................................... 21
Hydraulic Kit with Winch - PN 77077 .........................................................................22
Optional Power Unit Assembly - PN 77897 ............................................................... 23
Face Seal/O-Ring Size Chart......................................................................................24
Stability Procedure ...................................................................................................... 25
Crane Load Level Indicator ....................................................................................... 26
Decal Placement - PN 76876 .....................................................................................27
Chapter 3 - Assembly Drawings ................................................................................... 29
Base Assembly .............................................................................................................29
Mast Assembly .............................................................................................................30
Main Cylinder Assembly ............................................................................................. 31
Main Boom Assembly .................................................................................................32
TC23-2H Extension Boom Assembly ........................................................................... 33
TC23-3H Extension Boom Assembly ........................................................................... 34
1st/2nd Extension Cylinder Assembly ........................................................................ 35
3rd Extension Cylinder Assembly (TC23-3H) ............................................................. 36

Page iv | Stellar®TC23 Telescopic Crane Owner’s Manual
Introduction
A copy of this manual is provided with every crane and can be found in the hard plastic
manual case that is installed on the chassis. A copy of this manual shall remain with the
crane at all times.
Throughout the manual, three signal words will be used to bring attention to important
items:
A NOTICE signal word indicates a practice not related to physical injury.
A WARNING signal word indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
A DANGER signal word indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Information contained within this manual does not cover operation, maintenance, or
troubleshooting. Please refer to the General Light Duty Crane Manual for details on these
items.
This manual is not binding. Stellar Industries, Inc. reserves the right to change, at any
time, any or all of the items, components, and parts deemed necessary for product
improvement or commercial/production purposes. This right is kept with no requirement or
obligation for immediate mandatory updating of this manual.
In closing:
If more information is required or technical assistance is needed, or if you feel that any
part of this manual is unclear or incorrect, please contact the Stellar Customer Service
Department by phone at 800-321-3741 or email at [email protected].
WARNING
NOTICE
DANGER
For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at
800-321-3741
Hours: Monday - Friday, 8:00 a.m. - 5:00 p.m. CST
Or email at the following addresses:
Technical Questions, and Information [email protected]
Order Parts [email protected]
Warranty Information [email protected]

Stellar®TC23 Telescopic Crane Owner’s Manual | Page 1
45.6 in
9.8 in
12.2 in
(310 mm)
(21 mm)
(250 mm)
(1,158 mm)
27.3 in
(693 mm)
11.2 in
(285 mm)
79.9 in
(2,029 mm)
119.2 in
(3,027 mm)
(250 mm) (310 mm)
9.8 in
12.2 in
340º
23.22 in
(590 mm)
Hole Diameter
0.82 in
Rotational Clearance
(1,435 mm)
56.4 in
(1,649 mm)
64.9 in
(1,338 mm)
52.7 in
(989 mm)
38.93 in
(328 mm)
12.90 in
(490 mm)
19.27 in
(173 mm)
6.81 in
(859 mm)
33.81 in
(256 mm)
(189 mm)
(445 mm)
17.49
10.07 in
7.44 in
CG CG
Chapter 1 - Specications
Model TC23-2H Specications
TC23 Crane Model 2H
Crane Rating: 16,635 ft.lbs (23 kNm)
Max Lifting Capacity: 4,185 lbs (1,900 kg)
Max Reach: 9.94 ft (3.03 m)
Slewing Angle: 340°
Slewing Torque: 2,390 ft.lbs 3.2 kNm (0.33 m)
Operating Pressure: 2,755 psi 19.0 Mpa (190 bar)
Pump Capacity: 2.5 gpm (9.5 lpm)
Shipping Weight: 498 lbs (226 kg)

Page 2 | Stellar®TC23 Telescopic Crane Owner’s Manual
Model TC23-3H Specications
48.2 in
(1,223 mm)
79.9 in
(2,029 mm)
119.2 in
(3,028 mm)
12.9 in
(328 mm)
36.9 in
(937 mm)
158.6 in
(4,028 mm)
9.8 in
12.2 in
(310 mm)
(256 mm)
(189 mm)
(21 mm)
(445 mm)
(250 mm)
(250 mm) (310 mm)
9.8 in
12.2 in
340º
23.22 in
(590 mm)
Hole Diameter
0.82 in
Rotational Clearance
17.49
10.07 in
7.44 in
(1,435 mm)
56.4 in
(989 mm)
38.93 in
(328 mm)
12.90 in
(859 mm)
33.81 in
(173 mm)
6.81 in
(490 mm)
19.27 in
(1,435 mm)
56.4 in
CG CG
(1,321 mm)
52 in
TC23 Crane Model 3H
Crane Rating: 16,635 ft.lbs (12 kNm)
Max Lifting Capacity: 3,920 lbs (1,780 kg)
Max Reach: 13.22 ft (4.03 m)
Slewing Angle: 340°
Slewing Torque: 2,390 ft.lbs 3.2 kNm (0.33 m)
Operating Pressure: 2,755 psi 19.0 Mpa (190 bar)
Pump Capacity: 2.5 gpm (9.5 lpm)
Shipping Weight: 540 lbs (245 kg)

Stellar®TC23 Telescopic Crane Owner’s Manual | Page 3
0
0
9.84 ft
3 m
9.84 ft
3 m
6.56 ft
2 m
-6.56 ft
-2 m 6.56 ft
2 m
3.28 ft
1 m
-3.28 ft
-1 m
3.28 ft
1 m
13.12 ft
4 m
16.40 ft
5 m
13.12 ft
4 m
2H Version
TC23
1900 Kg
1.16 m
1010 Kg
2.09 m
715 Kg
3.03 m
4185 lbs
3.80 ft
2225 lbs
6.85 ft
1575 lbs
9.94 ft
TC23-2H Capacity

Page 4 | Stellar®TC23 Telescopic Crane Owner’s Manual
3H Version
TC23
0
0
9.84 ft
3 m
9.84 ft
3 m
6.56 ft
2 m
-6.56 ft
-2 m
6.56 ft
2 m
3.28 ft
1 m
-3.28 ft
-1 m
3.28 ft
1 m
13.12 ft
4 m
16.40 ft
5 m
19.68 ft
6 m
16.40 ft
5 m
13.12 ft
4 m
-9.84 ft
-3 m
1780 Kg
1.22 m
960 Kg
2.16 m
685 Kg
3.09 m
530 Kg
4.03 m
3920 lbs
4.00 ft
2115 lbs
7.08 ft
1510 lbs
10.13 ft
1165 lbs
13.22 ft
TC23-3H Capacity

Stellar®TC23 Telescopic Crane Owner’s Manual | Page 5
Installer Notice
According to Federal Law (49 cfr part 571), each nal-stage manufacturer shall complete
the vehicle in such a manner that it conforms to the standards in effect on the date of
manufacture of the incomplete vehicle, the date of nal completion, or a date between
those two dates. This requirement shall, however, be superseded by any conicting
provisions of a standard that applies by its terms to vehicles manufactured in two or more
stages.
Therefore, the installer of Stellar®Cranes and Bodies is considered one of the manufacturers
of the vehicle. As such a manufacturer, the installer is responsible for compliance with all
applicable federal and state regulations. They are required to certify that the vehicle is in
compliance with the Federal Motor Vehicle Safety Standards and other regulations issued
under the National Trafc and Motor Vehicle Safety Act.
Please reference the Code of Federal Regulations, title 49 - Transportation, Volume 5 (400-
999), for further information, or visit http://www.gpoaccess.gov/nara/index.html for the full
text of Code of Federal Regulations.
Chapter 2 - Installation
General Installation
This chapter is designed to serve as a general guide for the installation of a Stellar TC23
Crane on a Stellar Service Body. Each installation is considered unique so certain portions
of this chapter may or may not apply to your direct application. If a question should arise
during the installation process, please contact Stellar Customer Service at [phone].
This crane is designed for use with a Stellar Service Body installed on a vehicle that meets
the minimum chassis requirements of the crane. It is the installer’s responsibility to assure
that the crane is mounted on a platform that will support the maximum crane rating of this
crane.
Do not install this crane on a body not capable of handling the loads
imposed on it. Failure to do so may result in serious injury or death.
When installing welder units to the service bodies, it is highly
recommended that a surge protector is installed on the chassis batteries to protect the
crane radio receiver, wiring and other electronic devices from an unexpected electrical
spike or surge. Failure to do so could result in extensive damage to the service body and
crane electrical circuit.
WARNING
NOTICE

Page 6 | Stellar®TC23 Telescopic Crane Owner’s Manual
When using the torque data in the
chart, the following rules should be
observed:
• Bolt manufacturer’s particular
specications should be consulted
when provided.
• Flat washers of equal strength
must be used.
• All torque measurements are
given in foot-pounds. To convert
to inch-pounds, multiply by 12.
• Torque values specied are for
bolts with residual oils or no special
lubricants applied. If special
lubricants of high stress ability,
such as Never-Seez compound
graphite and oil, molybdenum
disulphite, colloidal copper or white lead are applied, multiply the torque values in the
charts by the factor .90. The use of Loctite does not affect the torque values listed above.
• Torque values for socket-head capscrews are the same as for Grade 8 capscrews.
• Do not use these values if a different torque value or tightening procedure is given for
a specic application. Torque values listed are for general use only. Check tightness of
fasteners periodically.
• Shear bolts are designed to fail under predetermined loads. Always replace shear bolts
with identical grade.
• Fasteners should be replaced with the same or higher grade. If higher grade fasteners
are used, these should only be tightened to the strength of the original.
• Tighten plastic insert or crimped steel-type lock nuts to approximately 110 percent of the
dry torque values shown in the chart below, applied to the nut, not to the bolt head.
Tighten toothed or serrated-type lock nuts to the full torque value. Note: “Lubricated”
means coated with a lubricant such as engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated without lubrication. Tighten lubricated bolts
to approximately 80% of dry bolts.
Size Bolt DIA Plain Plated Plain Plated Plated
(DIA-TPI) (Inches) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb)
5/16-18 0.3125 17 13 25 18 22
3/8-16 0.3750 31 23 44 33 39
7/16-14 0.4375 49 37 70 52 63
1/2-13 0.5000 75 57 105 80 96
9/16-12 0.5625 110 82 155 115 139
5/8-11 0.6250 150 115 220 160 192
3/4-10 0.7500 265 200 375 280 340
7/8-9 0.8750 395 295 605 455 549
1-8 1.000 590 445 910 680 823
1 1/8-7 1.1250 795 595 1290 965 1167
1 1/4-7 1.2500 1120 840 1815 1360 1646
1 3/8-6 1.3750 1470 1100 2380 1780 2158
1 1/2-6 1.500 1950 1460 3160 2370 2865
GRADE 5 GRADE 8 GRADE 9
Torque Data Chart

Stellar®TC23 Telescopic Crane Owner’s Manual | Page 7
Installation Overview
9.8 in
(250 mm)
9.8 in
(250 mm)
3.35 in
(85 mm)
ø
ø
2.36 in
(60 mm)
0.82 in
(21 mm)
4.72 in
(120 mm)
TC23 Mounting Detail
1. Use the dimensional specications to properly size and position the crane for mounting.
2. Use the detail on the following page to drill .82” diameter holes into the mounting plate.
3. Use a crane or lifting device capable of lifting the weight of the TC23 (See specications
for shipping weight details).
4. Connect straps or chain from the lifting device to the main boom of the TC23.
5. Remove motor to allow installation of the mounting bolts.
6. Use four (4) 0.75-10 UNC Grade 8 bolts, washers, and nuts. (See install drawing for details)
7. Using the lifting device, lower the TC23 just above the mounting surface and start the
bolts. Have someone assist in leveling the crane.
8. Secure the crane using the mounting hardware provided. Note: longer or shorter bolts
may be required – recommended thread engagement into crane base is 0.75” – use
grade 8, zinc plated bolts only.
9. Torque the bolts to proper torque.
10. Remove supporting crane.
11. Hook up hydraulics and electrical using the schematics provided later in this chapter.

Page 8 | Stellar®TC23 Telescopic Crane Owner’s Manual
.YTQNOITPIRCSEDTRAPMETI
2ESABCTRECAPSETALP390371
2C5942 PLATE SERIAL # TRUCK (NOT SHOWN) 1
38176 SCREW DRIVE #4X0.31 RND HD U ZINC 1
NOT SHOWN:
DECAL KIT 76876
LEVEL 76483
PN 76862
USE 0.75-10 UNC GRADE 8
BOLTS, WASHERS, & NUTS
NOTE: LENGTH NOT SPECIFIED DUE TO
VARYING MOUNTING REQUIREMENTS
2
1
3
BOTH SIDES
0.50 PLATE
0.25 PLATE
TUBE 3X3X0.38
BOLT TO
TRUCK FRAME
0.25 PLATE
WELD TO BODY
LONG SILL
0.19 PLATE
TC23 Installation Drawing - PN 76862
Flatbed Body Reinforcement
If it has been determined that the destination body won’t support
the crane with a fully rated load, the body must be reinforced. Use
1/4” llet welds and an AWS qualied welder to proceed as shown in
this drawing:

Stellar®TC23 Telescopic Crane Owner’s Manual | Page 9
3
1
2
.YTQNOITPIRCSEDTRAPMETI
188052 RADIO CTRL ASM 6 FCTN CDT TC13/23 1
276554 ISOLATOR RUBBER 0.25-20X1.13 4
30478 CAP SCR 0.25-20X0.50 HHGR5 4
NOT SHOWN: WIRE HARNESS 76678
REFER TO INST DWG 76541
Control Kit

Page 10 | Stellar®TC23 Telescopic Crane Owner’s Manual
RECEIVER - RADIO (PART OF 1)
RADIO CONTROLLER ASSEMBLY
WIRE HARNESS TBOOM CRANE
TRANSMITTER - RADIO (PART OF 1)
4
2
3
PD1
B
AB
AB
AB
A
ABABABAB
PROPORTIONAL
VALVE
ROTROT
CCW
CW
MAIN
DOWN UP
MAIN
RETRACT
EXTENSION
EXTEND
EXTENSION
AB
PRESSURE
TRANSDUCER
MOM OPTION
LATCH OPTION
HYD POWER UNIT OPTION
(GREEN HEAT SHRINK)
POWER
(GREEN)
GROUND (BLACK)
BA
BA
BA
ANTI TWO-BLOCK
BOOM
STOP
88052
Control Kit Installation Drawing

Stellar®TC23 Telescopic Crane Owner’s Manual | Page 11
RECEIVER - RADIO (PART OF 1)
RADIO CONTROLLER ASSEMBLY
WIRE HARNESS TBOOM CRANE
TRANSMITTER - RADIO (PART OF 1)
4
2
3
PD1
B
AB
AB
AB
A
ABABABABAB
MOM OPTION
LATCH OPTION
ROTROT
PROPORTIONAL
CW CCW
VALVE
MAIN
DOWN
EXTENSION
RETRACT
MAIN
UP
EXTENSION
EXTEND
WINCH
DOWN
WINCH
UP
POWER
(GREEN)
GROUND (BLACK)
HYD POWER UNIT OPTION
(GREEN HEAT SHRINK)
BA
BA
BA
ANTI TWO-BLOCK
BOOM
STOP
PRESSURE TRANSDUCER
88052
Control Kit with Winch Installation Drawing

Page 12 | Stellar®TC23 Telescopic Crane Owner’s Manual
TC Series Wiring Diagram

Stellar®TC23 Telescopic Crane Owner’s Manual | Page 13
.YTQNOITPIRCSEDTRAPMETI
1SENARCCTKCABREVOC649371
1SENARCCTTNORFREVOC749372
2KCOL83.0REHSAW32503
8TALFSSU52.0REHSAW04304
25RGHH00.3X61-83.0RCSPAC9490C5
45RGHH05.0X02-52.0RCSPAC87406
25RGHH57.0X02-52.0RCSPAC97407
2COLYN5RGHH02-52.0TUN33308
9 73943 VB 3 SECT W/PROP STER4GPM-8 VALVE DEUTSCH 1
PART NUMBERS NOT SHOWN:
76051, 4043, 75229, 75230
REFER TO INST DWG 76479
1
4
6
9
53
2
4
6
7
4
8
Hydraulic Kit - PN 75815

Page 14 | Stellar®TC23 Telescopic Crane Owner’s Manual
.YTQNOITPIRCSEDTRAPMETI
1SENARCCTKCABREVOC649371
1SENARCCTTNORFREVOC749372
2KCOL13.0REHSAW22503
8TALFSSU52.0REHSAW04304
25RGHH00.3X81-13.0RCSPAC0390C5
45RGHH05.0X02-52.0RCSPAC87406
25RGHH57.0X02-52.0RCSPAC97407
2COLYN5RGHH02-52.0TUN33308
9 72666 VB 4 SECT W/PROP STER4GPM-8 VALVE DEUTSCH 1
PART NUMBERS NOT SHOWN:
76051, 4043, 75229, 75230, 47083 (2)
1
4
6
9
53
2
4
6
7
4
8
PN 75818
Hydraulic Kit with Winch - PN 75818

Stellar®TC23 Telescopic Crane Owner’s Manual | Page 15
2
1
1
4
57
6
8
3
.YTQNOITPIRCSEDTRAPMETI
4THGIARTSBROM-JM4-4GTF484641
409BROAM-JM4-4GTF028572
3D0511 FTG 4 MORB PLUG HOLLOW HE
X1
109BROF-BROAM4-4GTF718154
539780 GAUGE OIL LF 2.5 0-5000 CBM SA
E1
1THGIARTSBROM-JM6-6GTF511746
1THGIARTSBROM-JM6-4GTF380747
8 73943 VB 3 SECT W/PROP STER4GPM-8 VALVE DEUTSCH 1
Hydraulic Kit -Valve Bank

Page 16 | Stellar®TC23 Telescopic Crane Owner’s Manual
5
1
5
3
2
5
3
HYDRAULIC SCHEMATIC
P&T SAE #6
Others SAE #4
EUQROTYTQNOITPIRCSEDTRAPMETI
SBLTF72-32175942EVLAVFEILER573521
25376SEAL KIT 25375
225381 VALVE FLW CTRL PRP/JP04C3150N 0-4120-22 FT LBS
25369SEAL KIT 24960/25381
325377 VALVE SOLND 3 POS 4 WAY TA ND G02571 322FT LBS
444532 COIL 12VDC DUETSCH CAP012H 122 FT LBS
555126 COIL 12VDC DUETSCH CCP012H 63FT LBS
PN 73943
Valve Bank - PN 73943